Apparatus and method for low temperature thermal stripping of volatile organic compounds from soil

ABSTRACT

Apparatus and method for removing volatile and semivolatile organic contaminants from natural soil containing moisture by sealing the soil in a stripping conveyor against contact with air and vapor stripping the contaminants at a temperature below the boiling temperatures of the contaminants.

The Government has rights in this invention pursuant to Contract No.DAAK11-82-C-0017 awarded by the U.S. Army Armament, Munitions, andChemical Command. The invention described herein may be manufactured,used and licensed by or for the Government for governmental purposeswithout the payment to me of any royalty thereon.

This invention relates to an apparatus and method of removing volatileand semi-volatile hazardous organic contaminants from natural soil. Theinvention more particularly relates to the treatment of soil containingsuch hazardous organic contaminants whereby the contaminants are removedand the soil may be returned to the earth without pollution to theenvironment. The invention further relates to the removal from the earthof soil already polluted by the presence of hazardous organiccontaminants, the treatment of such soil for removal of thecontaminants, and the return of the soil to the earth.

In recent years it has been an important objective to treat soilscontaminated as a result of industrial operations, waste, accidents orthe like, and many difficulties have been experienced because ofproblems encountered in materials handling, high operational costs, anddifficulty in achieving high levels of contaminant removal.

Contamination of soils involving volatile organic compounds has becomeone of the predominant environmental concerns. Trichloroethylene isperhaps the most frequently found contaminant; however, other volatileorganic compounds such as dichloroethylene, tetrachloroethylene andxylene have also been found. If allowed to remain in the soil, thesecompounds can migrate to contaminate underlying ground waters and canlead to other hazardous conditions as well.

Although thermal stripping of dry soil has been attempted, highstripping temperatures are necessary to assure release and removal ofthe higher boiling organic contaminants, with serious operating and costdisadvantages.

In an entirely different field, in conjunction with off shore and inlanddrilling barges and rigs, drill cuttings have been treated to transformthem from a wet oily condition to a clean substantially oil-freecondition, by feeding them to a heating chamber having a non-oxidativeenvironment, thereby vaporizing the hydrocarbon residue and dischargingthe product to the atmosphere. The patent to Sample, Jr. U.S. Pat. No.4,139,462 discloses the use of a twin screw "Holo-Flite" heating vesselwhich is an indirect heat exchanger and screw conveyor that continuouslyheats the oil well drilling mud as the material is continuously movedthrough it. Problems are encountered, however, when such a drilling mudprocess is attempted to be applied to contaminated natural soils.

It is accordingly an object of this invention to provide an apparatusand method of removing volatile and semi-volatile hazardous organiccontaminants from natural soil, to produce substantially completeremoval of the contaminants, all at a relatively low temperature wellbelow the vaporization temperature of the higher boiling organiccontaminants. Another object of this invention is to provide such amethod wherein the hazardous organic contaminants are removed withsafety and may be discharged without environmental pollution.

Other objects and advantages of this invention, including the simplicityand economy of the same and the ease with which it may be applied to avariety of soils and combinations of contaminants contained in the soilswill further become apparent hereinafter in the drawings whereof:

FIG. 1 represents a schematic diagram showing one preferred formaccording to which the invention may be practiced.

FIG. 2 shows a front elevational end view of a mobile form of apparatusin accordance with the present invention.

FIG. 3 depicts a top plan view of mobile apparatus utilized inaccordance with the present invention.

FIG. 3A represents an exploded view of twin screw processing apparatustaken generally from the phantom circle as shown in FIG. 3.

FIG. 4 is a side elevational view of mobile soil processing apparatus ofthe present invention.

FIG. 5 represents a schematic cross sectional view of apparatus utilizedin accordance with the present invention.

FIG. 6 is a schematic .[.slide.]. .Iadd.side .Iaddend.view of a portionof mobile soil processing apparatus of the present invention.

FIG. 7 shows a front elevational end view of mobile soil processingapparatus manifesting other aspects of the invention.

Although specific terms will be used for the sake of clarity inhereafter describing the particular form of the invention selected forillustration in the drawings, it will be realized that this descriptionis not intended to limit the scope of the invention or to exclude theuse of a wide variety of modifications.

Turning now to the drawings in general and FIGS. 1 and 2 in particular,the number 10 designates a feed hopper for the contaminated soil S,which may be removed from the earth by conventional earth removing means18 and stored in the hopper 10, here shown as having a bottom dischargepipe 11. The number 12 designates an inclined conveyor, which may be ascrew conveyor or a continuous belt conveyor, for example, having asealed connection 13 to the bottom of the bottom discharge pipe 11.

At its upper end, the inclined conveyor 12 discharges in sealedrelationship into a feed device, such as a pug mill 14, which in turn isconnected sealingly to the inlet of a twin screw, indirectly heatedprocessor 15. The processor 15 may be of the "Holo-Flite" type asdisclosed in U.S. Pat. Nos. 2,731,241 and 2,753,159, provided withhollow flights having internally arranged passageways for conducting aheat transfer fluid such as hot oil, steam or the like (see FIG. 3A).Means are provided for supplying heat transfer fluids such as hot oil tothe twin screw processor, comprising a hot transfer fluid or oil heater16 having an outlet pipe 17 connected to the twin screw processor 15 tosupply hot oil for indirect heating of the soil processed therein. Theexit pipe 20 for hot oil is arranged to return the oil to the inlet 21of the oil heater 16. The oil heater 16 produces combustion gas whichexits through the flue pipe 22 and to the atmosphere. A branch pipe 23,provided with a damper 24, extends from the flue pipe 22 to the upperspace within the twin screw processor 15, above the screw flightscontained therein. It is an important and advantageous feature of thisinvention that the branch pipe 23 is connected at the earth exit end ofthe twin screw processor, for reasons which will become apparenthereinafter.

Located approximately at a middle portion of twin screw processor 15 isan exhaust duct 25 provided with a flow meter 26 and a temperaturesensor 27. A damper 30 is provided in the exhaust duct 25, which alsoincludes an induced draft blower 31 having its outlet connected toexhaust gas treatment chamber 32 the outlet of which communicates withthe atmosphere.

As shown in FIG. 2, it will now be appreciated that, in operation, thesoil S is conducted in a sealing relationship through the seal 13 intothe inclined conveyor 12 and then, still in a sealed relationship,through the pug mill 14 into the sealed twin screw processor 15, whereit is processed in intimate contact with the intermeshing worm flightswhich are indirectly heated through internal passageways with the hotoil introduced through the line 17 from the oil heater 16. Processedsoil exits processor 15 by way of earth transporter 19 as shown in FIG.5.

Referring to FIGS. 3 and 4, combustion gases from the oil heater 16 flowthrough the branch pipe 23 and the damper 24 into the earth exit end ofthe twin screw processor 15 and are then caused to flow above therotating screw flights in a countercurrent manner with respect to theflow of the earth being processed. The combustion gases flow out of thetwin screw processor 15 through the exhaust duct 25, past the flow meter26 and temperature sensor 27, into the inlet of the induced draft blower31 and then out through the exhaust gas treatment 32 to the atmosphere.Exhaust gas treatment 32 may consist of removing dust, wet scrubbing forremoval of acid gases, burning organics, burning organics followed bywet scrubbing, adsorbing a portion of the hazardous constituents onactivated carbon, recovery of hazardous constituents by condensation orrecovery by condensation followed by adsorption on activated carbon.

Alternatively the exhaust gas may be conducted through duct 34 tocombustion air inlet duct 35 and recycled to oil heater 16 by blower 36(See FIGS. 1 and 3). This is advantageous in utilizing the combustionprocess in oil heater 16 for disposal (or use as an energy source) ofthe organic contaminants from the soil.

It has been discovered that it is important to maintain a moisturecontent in the soil and that this moisture performs a vapor strippingoperation which allows even the higher boiling organic contaminants tobe removed at temperatures far below their boiling points. Moisture isretained in the soil by virtue of the sealing relationship at 13 and 14in the drawing, assuring that the soil fed into the twin screw processor15 contains sufficient moisture to serve the aforesaid vapor strippingoperation.

It is an important advantageous feature of this invention that thecombustion gas from the oil heater 16 is a non-oxidizing gas, namely,that it is either slightly reducing or inert, and that it is introducedfor countercurrent flow in the twin screw processor 15, with respect tothe flow of the soil being processed. In this manner the non-oxidizingcombustion gas at its highest temperature contacts the process soil whensuch soil is also at its highest temperature. By contrast, thenon-oxidizing combustion gas is at its coolest temperature when itcontacts the incoming soil, which is also at its coolest temperature.This avoids excessive removal of moisture from the incoming soil andassures the presence of sufficient moisture to perform the vaporstripping operation throughout the length of the twin screw processor15.

It is also an important and advantageous feature of this invention thatthe induced draft blower 31, operating under the control and in responseto the determinations of the flow meter 26 and the temperature sensor27, provides a negative pressure within the twin screw processor 15,preventing fugitive emissions of the hazardous organic constituents.This feature combined with the utilization of the sealed system asheretofore described provides highly advantageous vapor stripping andsafety as well.

It will be appreciated that the settings of the dampers 24 and 30 areregulated automatically in response to the determinations of flow meter26 and temperature sensor 27, all in a manner known in the art per seand not shown in the drawing in order to avoid unnecessarycomplications.

It will also be observed that a suction line 33 extends from the sealedinclined conveyor 12 to the exhaust duct 25. This applies negativepressure to the inclined conveyor 12, preventing fugitive emissions ofhazardous organic constituents which may be released from the soil inthe inclined conveyor 12.

It will accordingly be appreciated that, in accordance with thisinvention, soil containing volatile and semivolatile hazardous organiccontaminants is treated by removing the soil from the earth byconventional earth moving means such as a front end loader or anexcavator 18 as shown in FIG. 2, and placing it in a soil container suchas the feed hopper 10, sealing the soil against substantial contact withthe air and conveying the soil in sealed condition to a strippingconveyor provided with heated flights, heating the moisture contained inthe soil by intimate contact with the heated surfaces in the strippingconveyor 15, vapor stripping the hazardous organic contaminants from thesoil in the twin screw processor 15 at a temperature below the boilingtemperatures of the soil contaminants with non-oxidizing combustiongases which are conducted countercurrently over the soil subjected tovapor stripping in the stripping conveyor, and controlling thetemperature and flow rate of the countercurrent sweep to maintainmoisture continuously present at the surface of the soil as and afterthe soil enters the stripping conveyor. It will further be appreciatedthat the provision of a negative pressure over the soil in the sealedconveyor, when non-oxidizing sweep gases are countercurrently conductedwith respect to the direction of movement of the soil, not only providesa negative pressure in a manner to prevent fugitive emissions of thehazardous organic constituents but also enhances release of moisturefrom the soil and enhances the vapor stripping effect of the moisture inaccomplishing removal of higher boiling organic contaminants at atemperature far below the boiling points of these contaminants. It hasbeen found that the soil to be processed should reside within theprocessor for between about 30-90 minutes with a residence time of aboutbetween 45-60 minutes being preferred. The temperature of the exitingprocessed soil should be between about 120°-450° F. with a temperatureof about between 140°-220° F. being preferred.

It has been determined that removal of as much as 99.99% of all organiccontaminants has been continuously achieved at a production ratereaching a practical level for treatment of natural soil.

Although this invention has been described with reference to a specificform selected for illustration in the drawings, it will be appreciatedthat many modifications may be made, that certain steps may be performedindependently of other steps, and that a wide variety of equivalentforms of apparatus may be utilized, all without departing from thespirit and scope of this invention, which is defined in the appendedclaims.

I claim:
 1. In a method of removing volatile and semi-volatile hazardousorganic contaminants from natural soil containing moisture and suchcontaminants the steps which comprise:(a) removing the soil from theearth and placing it in a soil container; (b) sealing the soil againstsubstantial contact with air and conveying the soil in sealed conditionto a stripping conveyor with heated flights, (c) vapor stripping saidhazardous organic contaminants from said soil in said conveyor at atemperature below the boiling temperatures of said contaminants bydriving said moisture out of said soil by volatilization of saidmoisture; (d) separately by combustion of fuel firing a heater forheating said stripping conveyor .[.and thereby generating non-oxidizingcombustion gases.].; (e) sweeping .[.said combustion.]..Iadd.non-oxidizing sweep .Iaddend.gases countercurrently over the soilsubjected to vapor stripping in said stripping conveyor; and (f)controlling the temperature and flow rate of said countercurrent sweepto maintain moisture continuously present at the surface of the soil asand after said soil enters said stripping conveyor.
 2. The methoddefined in claim 1, further comprising intermixing portions of said soilwithin said stripping conveyor with a twin screw conveyor withinternally heated intermeshing flights.
 3. The method defined in claim1, further comprising applying a negative pressure to a sealed soilconveyor provided to transport the soil from the soil container to thestripping conveyor, in a manner to prevent fugitive emissions of thehazardous organic constituents.
 4. The method defined in claim 3,further comprising applying said negative pressure to said soil conveyorfrom the exhaust from said stripping conveyor.
 5. The method defined inclaim 1, further including the step of maintaining the countercurrentlyflowing sweep gases at less than atmospheric pressure in said strippingconveyor.
 6. The method defined in claim 1, further including the stepsof removing and purifying the countercurrent sweep gases and dischargingthem to the atmosphere.
 7. The method defined in claim 6, wherein thepurifying step comprises removing dust.
 8. The method defined in claim6, wherein the purifying step comprises wet scrubbing for removal ofacid gases from said gases.
 9. The method defined in claim 6, whereinthe purifying step comprises burning organics contained in said gases.10. The method defined in claim 9, followed by the step of wet scrubbingsaid gases.
 11. The method defined in claim 6, wherein the purifyingstep comprises adsorbing at least some of the hazardous constituents onactivated carbon.
 12. The method defined in claim 6, including thefurther step of recovering at least one of the hazardous constituents bycondensation.
 13. The method defined in claim 12, followed by thefurther step of adsorption on activated carbon.
 14. The method definedin claim 1, further including the step of returning the purified naturalsoil to the earth.
 15. The method defined in claim 1, wherein the stepof heating the moisture contained in the soil comprises burning a fuelwith combustion air, and wherein countercurrent sweep gases are returnedto said burning step along with said combustion.
 16. Apparatus forremoving volatile and semi-volatile hazardous organic contaminants fromnatural soil containing moisture and such contaminants, comprising:(a) asoil container for the earth; (b) sealing means for sealing the soilagainst substantial contact with air; (c) a stripping conveyorcomprising a screw conveyor with internally heated intermeshing flights;(d) means for conveying soil in sealed condition, including a sealedsoil conveyor provided to transport soil from the soil container to thestripping conveyor; (e) means for applying a negative pressure over soilin said sealed conveyor in a manner to prevent fugitive emissions of thehazardous organic constituents; (f) means for heating the moisturecontained in the soil by intimate contact with heated surfaces in saidstripping conveyor, thereby vapor stripping said hazardous organiccontaminants from said soil in said conveyor; (g) a fuel burnerconnected for heating said stripping conveyor and thereby generatingnon-oxidizing combustion gases; (h) means for conveying .[.saidcombustion.]. .Iadd.non-oxidizing sweep .Iaddend.gases countercurrentlyover the soil subjected to vapor stripping in said stripping conveyor;and (i) control means connected for controlling the temperature and flowrate of said countercurrent sweep to maintain moisture continuouslypresent at the surface of the soil as and after said soil enters saidstripping conveyor.
 17. The apparatus defined in claim 16, wherein saidnegative pressure is applied from the exhaust from said strippingconveyor to said soil conveyor.
 18. The apparatus defined in claim 16,further including means for maintaining the countercurrently flowingsweep gases at less than atmospheric pressure in said strippingconveyor.
 19. The apparatus defined in claim 16, further including meansfor removing and purifying the countercurrent sweep gases anddischarging them to the atmosphere.
 20. The apparatus defined in claim19, wherein the removing and purifying means comprises means forremoving dust.
 21. The apparatus defined in claim 19, wherein thepurifying means comprises a wet scrubber for removal of acid gases fromsaid gases.
 22. The apparatus defined in claim 19, wherein the purifyingmeans comprises a burner for burning organics contained in said gases.23. The apparatus defined in claim 22, comprising a wet scrubberdownstream of said burner.
 24. The apparatus defined in claim 19,wherein the purifying means comprises means for adsorbing at least someof the hazardous constituents on activated carbon.
 25. The apparatusdefined in claim 19, further including means for recovering at least oneof the hazardous constituents by condensation.
 26. The apparatus definedin claim 25, further including means for adsorption on activated carbon.27. The apparatus defined in claim 16, further including conveyor meansfor returning the purified natural soil to the earth.